INSTALLATION INSTRUCTIONS: HARLEY-DAVIDSON TOURING HI-OUTPUT CARBON PART# 16465/46465 Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your Vance & Hines exhaust is designed and crafted for performance, quality, and style. Please follow the instructions below, check exhaust system for missing or damaged parts and if you need any assistance please contact our technical support line (562) 921-7461. PARTS LIST ITEM NO. PART NO. DESCRIPTION QTY. 1 D266RC/D272RP RT. MUFFLER 1 2 D267RC/D273RP LT. MUFFLER 1 3 758-P LT. BRACKET 1 4 757-P RT. BRACKET 1 5 A195HW NUTPLATE 2 6 A240HW FLANGE BOLT 4 7 D415HC/ D416HP HEATSHIELD 2 8 A519HW 3 BAND CLAMP 2 9 A335GW 2 BAND CLAMP 2 7 3 2 4 1 HARDWARE 8 9 5 6 *NOT TO SCALE Page 1 of 5
TOOLS REQUIRED SLOT SCREWDRIVER RATCHET WITH 4 EXTENSION 1/2, 9/16 SOCKETS, 7/16 DEEP SOCKET 5/16 NUT DRIVER 1/2, 9/16 COMBINATION WRENCHES STOCK EXHAUST SYSTEM REMOVAL 1. Remove both saddlebags and set them aside. 2. Loosen the bolt from the pinch clamp on the front end of each muffler. 3. Working with one muffler at a time, support the muffler (assistance may be required) while removing the 5/16 bolts from the saddlebag support and slide muffler off of the head pipe. 4. Repeat the process for the opposite muffler. NOTE: It may be necessary to use a penetrating lubricant to loosen the muffler from the head pipe. 5. Leaving the grommets in place, remove the stock mounting brackets from the rubber grommets located on the saddlebag supports. NOTE: Inspect the grommets to verify that they are in good condition, if the grommets are damaged they will need to be replaced. Page 2 of 5
VANCE & HINES EXHAUST INSTALLATION 1. Install the muffler brackets 757-P on the right side and 758-P on the left side. (See Figure 1). 2. Install the heat shield cones to the mufflers with the 3 T-bolt band clamp, facing down and leave loose. (See Figure 2) 3. Install the 2 band clamps over the front of each muffler inlet so that the bolt is to the inside and the nut is facing down. 4. Slide right side muffler on. Note: Dent will be on the inside, heat shield cone goes over the header heat shields. 5. Slide nut plates inside the brackets welded to backside of muffler bodies and attach the muffler to the muffler support bracket #757-P using two 5/16 flange bolts (supplied). Finger tighten only. 6. Repeat installation procedure for opposite muffler. 7. Align mufflers bodies then torque the band clamps to 40-44 ft. lbs. Adust the heat shield con/clamp opening to face towards the rear tire. Tighten the heat shield cone T-bolt clamp also to, torque 90-125 ft. lbs. Slide the muffler support bracket as far as possible rearward before tightening the two flange bolts. Torque the bolts to 18 ft. lbs. 8. Replace the saddlebags. 9. After installation and before starting motorcycle, completely clean pipes and mufflers with cleaning solvent and a clean, soft cloth that will not leave a residue. NOTE: Any residue, oil, or fingerprints will stain the chrome when the metal heats up. 10. Be sure to tighten all hardware before starting your motorcycle. 11. IMPORTANT: AFTER TEST RIDE LET PIPES COOL DOWN AND RE-TORQUE MUFFLER BAND CLAMP. Page 3 of 5
EXHAUST CARE 1. When installing a new set of chrome pipes, make sure your hands are clean and free of oil. After installation, thoroughly clean pipes with a soft cloth and cleaning solvent that will leave no residue (chrome wax/polish, glass cleaner, alcohol, ammonia, etc.) before starting the motorcycle. 2. Avoid long periods of idling as this can cause discoloration. 3. Intake leaks can cause the engine to run lean and overheat, this could lead to discoloration. 4. Make sure there are no exhaust leaks at the junction of the exhuast pipes and the cylinder head. We recommend replacing gaskets if they are worn. EXHAUST CARE (BLACK) 1. When installing a new set of black pipes, make sure your hands are clean and free of oil. After installation, thoroughly clean pipes with warm soapy water and a soft cloth. Dry with a clean towel to remove any residue before starting the motorcycle. Do NOT use anything abrasive to clean the pipes. 2. Avoid long periods of idling as this can cause discoloration. 3. Intake leaks can cause the engine to run lean and overheat, this could lead to discoloration. 4. Make sure there are no exhaust leaks at the junction of the exhuast pipes and the cylinder head. We recommend replacing gaskets if they are worn. FIGURE 1 (LEFT SIDE) WHEEL GROMMET SLIP-ON MUFFLER 758-P FRAME FIGURE 2 (CLAMP DIRECTION) Page 3 of 5
Emissions Notice: In California, in order to meet Air Resources Board emissions requirements, certain aftermarket part applications have been identified as replacements, and others have received ARB Executive Orders. All other emissions related aftermarket parts are for competition use only. A list of replacement parts and EO parts, and corresponding fitment is provided at vanceandhines.com/california. Warranty: All Vance & Hines products are warranted against defects in material and workmanship for a period of 90 days. This warranty does not cover discoloration or rust. This warranty shall be limited to the repair or replacement of the product, which may be proven defective under normal use. Vance & Hines will not warranty any system that has been abused, misused, improperly installed or modified. Dealers or distributors are not authorized to make dispositions binding upon Vance & Hines. Vance & Hines will not be responsible for any labor charges incurred in removing or replacing any system under warranty. A return authorization number and a copy of the original purchase invoice must accompany all returns. Parts returned without a return authorization may be refused. Page 5 of 5 13861 ROSECRANS AVENUE / SANTA FE SPRINGS, CA 90670 SALES: (562) 921-5388 TECHNICAL: (562) 926-5291 FAX: (562) 802-0110